Suction motor housing for an upright surface cleaning apparatus

ABSTRACT

An upright surface cleaning apparatus comprises a floor cleaning head having a dirty air inlet, and an air flow passage extending from the dirty air inlet to a clean air outlet. An upright section is moveably mounted to the surface cleaning head between a storage position and an in use position. The upright section comprises a filtration member and a suction motor provided in the air flow passage. The suction motor has an air inlet end, an opposed distal end, and an air inlet direction. The upright section further comprises a motor housing. The motor housing comprises a motor section in which the suction motor is provided. The motor section has a first end at the air inlet end of the suction motor and an opposed second end at the distal end of the suction motor. An openable post motor filter chamber is provided in the motor housing and has an inlet end and an outlet end. At least a portion of the filter chamber is provided in the motor section. The inlet end includes a finger guard and the filter chamber has a direction of airflow that is transverse to the air inlet direction of the suction motor. A post motor HEPA filter is removably mounted in the filter chamber.

FIELD

The disclosure relates to surface cleaning apparatuses, such as vacuum cleaners. Particularly, the disclosure relates to upright surface cleaning apparatuses.

INTRODUCTION

The following is not an admission that anything discussed below is prior art or part of the common general knowledge of persons skilled in the art.

Various constructions for surface cleaning apparatus such as vacuum cleaners are known. Currently, many surface cleaning apparatus are constructed using at least one cyclonic cleaning stage. The air is drawn into the vacuum cleaner through a dirty air inlet and conveyed to a cyclone inlet. The rotation of the air in the cyclone results in some of the particulate matter in the airflow stream being disentrained from the airflow stream. This material is then collected in a dirt collection chamber, which may be at the bottom of the cyclone or in a dirt collection chamber exterior to the cyclone chamber (see for example WO2009/026709 and U.S. Pat. No. 5,078,761). One or more additional cyclonic cleaning stages and/or filters may be positioned downstream from the cyclone.

SUMMARY

The following summary is provided to introduce the reader to the more detailed discussion to follow. The summary is not intended to limit or define the claims.

According to one aspect, an upright surface cleaning apparatus is provided with a suction motor housing that includes a post motor filter chamber. The post motor filter chamber is positioned spaced from but facing the suction motor. The air accordingly will travel from the air treatment member or members to the suction motor inlet. The air will travel through the fan of the suction motor and then by or through the motor section to cool the motor. The air will then travel laterally, and possibly upwardly and laterally, to the post motor filter. This constructions permits a reduction in the size of the suction motor housing.

Traditionally, upright surface cleaning apparatus have had large, bulky frames or upper housings. The upper housing has a recess for removably receiving a cyclone. The housing has also incorporated air flow passages (e.g., from a dirty air inlet to a cyclone inlet and from a cyclone outlet to a suction motor inlet). This structure increases the weight of an upright vacuum cleaner and also reduces the portability of an upright vacuum cleaner for the elderly or the infirm. A reduction in the size of the suction motor housing reduces the weight and increases the portability of the surface cleaning apparatus.

In a preferred embodiment, the suction motor is mounted on the upright section of the vacuum cleaner (e.g., the portion that comprises the push handle) and is spaced from the floor cleaning head. Such a construction is advantageous as it permits the floor cleaning head to extend further under furniture (e.g., floor cleaning head may be passed under furniture until the bottom of the upright section contact the furniture). However, if the components of the vacuum cleaner (e.g., the motor and the cyclone housing) are too high on the handle, then the hand weight of the vacuum cleaner during operation will increase thereby decreasing the usability of the vacuum cleaner. Reducing the height of the suction motor housing permits the suction motor to be provided on the handle, thereby reducing the height of the floor cleaning head and increasing the ability of the floor cleaning head to clean under furniture. At the same time, the components on the vacuum cleaner may be mounted lower thereby reducing hand weight.

According to this aspect, an upright surface cleaning apparatus comprises a floor cleaning head having a dirty air inlet, and an air flow passage extending from the dirty air inlet to a clean air outlet. An upright section is moveably mounted to the surface cleaning head between a storage position and an in use position. The upright section comprises a filtration member and a suction motor provided in the air flow passage. The suction motor has an air inlet end, an opposed distal end, and an air inlet direction. The upright section further comprises a motor housing. The motor housing comprises a motor section in which the suction motor is provided. The motor section has a first end at the air inlet end of the suction motor and an opposed second end at the distal end of the suction motor. An openable post motor filter chamber is provided in the motor housing and has an inlet end and an outlet end. At least a portion of the filter chamber is provided in the motor section. The inlet end includes a finger guard and the filter chamber has a direction of airflow that is transverse to the air inlet direction of the suction motor. A post motor HEPA filter is removably mounted in the filter chamber.

The inlet end of the filter chamber may be positioned adjacent the suction motor. At least a portion of the inlet end of the filter chamber may be laterally spaced from and may face the suction motor.

The surface cleaning apparatus may further comprise a pre-motor filter positioned at the air inlet end of the suction motor. The pre-motor filter may have a direction of airflow that is aligned with the air inlet direction of the suction motor.

The filtration member may comprise a cyclone. The cyclone may comprise an air inlet and an air outlet, and the air outlet of the cyclone may be spaced from and may face the pre-motor filter. The air inlet end of the filter chamber may be spaced less than 3 inches from the suction motor, more specifically less than 1.5 inches from the suction motor.

According to another aspect, another upright surface cleaning apparatus is provided. The surface cleaning apparatus comprises a floor cleaning head having a dirty air inlet. An air flow passage extends from the dirty air inlet to a clean air outlet. An upright section is moveably mounted to the surface cleaning head between a storage position and an in use position, and includes a motor housing. A filtration member and a suction motor are provided in the air flow path. The suction motor has an air inlet end, an opposed distal end, and an air inlet direction. An openable post motor filter chamber is provided in the motor housing and has an inlet end and an outlet end. At least a portion of the inlet end is laterally spaced from and faces the suction motor. The inlet end includes a finger guard. A post motor HEPA filter is removably mounted in the filter chamber.

The inlet end of the filter chamber may be positioned adjacent the suction motor.

The motor housing may comprise a motor section in which the suction motor is provided. The motor section may have a first end at the air inlet end of the suction motor and an opposed second end at the distal end of the suction motor. At least a portion of the filter chamber may be provided in the motor section.

The surface cleaning apparatus may further comprise a pre-motor filter positioned at the air inlet end of the suction motor. The pre-motor filter may have a direction of airflow that is aligned with the air inlet direction of the suction motor.

The filter chamber may have a direction of airflow that is transverse to the air inlet direction of the suction motor.

The filtration member may comprise a cyclone. The cyclone may comprise an air inlet and an air outlet, and the air outlet may be spaced from and may face the pre-motor filter. For example, the air inlet end of the filter chamber may be spaced less than 3 inches from the suction motor, more specifically less than 1.5 inches from the suction motor.

DRAWINGS

Reference is made in the detailed description to the accompanying drawings, in which:

FIG. 1 a is a perspective illustration of an embodiment of a surface cleaning apparatus in a storage position;

FIG. 1 b is a perspective illustration of the surface cleaning apparatus of FIG. 1 a, in an in-use position;

FIG. 2 is a cross section taken along line 2-2 in FIG. 1;

FIG. 3 is a top perspective illustration of a motor housing of the surface cleaning apparatus of FIG. 1 a;

FIG. 4 is a top perspective illustration of the surface cleaning apparatus of FIG. 1 a, with a filtration member housing removed, and a pre-motor filter exploded from the motor housing;

FIG. 5 is a perspective illustration of the surface cleaning apparatus of FIG. 1, showing a grate and a post-motor filter removed from the surface cleaning apparatus;

FIG. 6A is a cross section taken along line 6A-6A in FIG. 1; and

FIG. 6B is a cross section taken along line 6B-6B in FIG. 1; and

DETAILED DESCRIPTION

Referring to FIG. 1 a, a first embodiment of a surface cleaning apparatus 100 is shown. In the embodiment shown, the surface cleaning apparatus 100 is an upright surface cleaning apparatus (otherwise referred to as an upright vacuum cleaner). In alternate embodiments, the surface cleaning apparatus may be another suitable type of surface cleaning apparatus, such as a canister type vacuum cleaner, and hand vacuum cleaner, a stick vac, a wet-dry type vacuum cleaner or an carpet extractor.

Referring still to FIG. 1 a, the surface cleaning apparatus 100 has a dirty air inlet 102, a clean air outlet 104, and an air flow passage extending therebetween. In the embodiment shown, the dirty air inlet 102 is provided in a floor cleaning head 106. From the dirty air inlet 102, the airflow passage extends through the floor cleaning head 106, and through an air conduit 108, to an upright section 110. The clean air outlet 104 is provided in the upright section 110. In the embodiment shown, the air conduit 108 includes a pivoting joint member 112 connected to the floor cleaning head 106, a lower upflow duct 114, an upper upflow duct 116, a hose 117, and an elbow joint 118. The elbow joint 118 is in airflow communication with the upright section 110. In alternate embodiments, the air conduit 108 may be of another configuration. For example, only a pivoting joint member 112, a lower upflow duct 114, and an elbow joint 118 may be provided.

A handle 119 is mounted to the upper upflow duct 116, for manipulating the surface cleaning apparatus 100.

The upright section 110 is moveably mounted to the surface cleaning head 106 between a storage position, shown in FIG. 1 a, and an in-use position, shown in FIG. 1 b. In order to move the upright section from the storage position to the in-use position, the pivoting joint member 112 may be pivoted about a horizontal axis.

Referring now to FIG. 2, the upright section 110 includes a filtration member housing 120, and a motor housing 122. The filtration member housing 122 houses filtration member 124, which is positioned in the airflow passage downstream of the dirty air inlet 102 for removing particulate matter from air flowing through the airflow passage. The motor housing 122 houses a suction motor 126, which is provided in the airflow passage downstream of the filtration member 124 for drawing air through the airflow passage.

In the embodiment shown, the upright section 110 is supported by and mounted to the lower upflow duct 114. Particularly, a mount 128 is provided which mounts the upright section 110 to the lower upflow duct 114. The mount 128 may be of any suitable configuration. In the embodiment shown, the mount 128 is integrally formed with the motor housing 122, and is mountable to the lower upflow duct 114. The mount 128 may be mountable to the lower upflow duct 114 in any suitable manner, and is preferably removably mountable to the lower upflow duct 114.

In the embodiment shown, the filtration member housing 120 includes a sidewall 130, a top wall 132, and a bottom wall 134. The motor housing 122 includes a sidewall 136 and a bottom wall 138, and an open top 140. The sidewall 136 of the motor housing 122 is removably mounted to the bottom wall 134 of the filtration member housing 120, so that the bottom wall 134 of the filtration member housing 120 seals the open top 140 of the motor housing 122. The sidewall 136 of the motor housing 122 may be removably mounted to the bottom wall 134 of the filtration member housing 120 in any suitable manner, such as by one or more latch members 142.

In the embodiment shown, as the motor housing 122 is mounted to the lower upflow duct 114, and the filtration member housing 120 is removably mounted to the motor housing 122 above the motor housing 122, the filtration member housing 120 may be removed from the motor housing by unlatching the one or more latch members 142, and lifting the filtration member housing 120 off of the motor housing 122. When this is done, the filtration member housing 120 will be generally sealed, except for any airflow passages leading to or from the filtration member housing 120, and the top 140 of the motor housing 122 will be open.

Referring still to FIG. 2, in the embodiment shown, the filtration member 124 is a cyclone 144. In alternate embodiments, the filtration member 124 may be, for example, a filter, such as a filter bag or a foam filter. In further alternate embodiments, the filtration member 124 may include a plurality of cyclones, or a plurality of cyclonic stages.

The cyclone 144 may be of any suitable configuration. In the embodiment shown, the cyclone 144 extends along a longitudinal axis 146, which is generally vertically extending, and includes a generally cylindrical cyclone wall 148, which defines a cyclone chamber 150. The upper end 152 of the cyclone wall 148 is open, and the lower end 154 of the cyclone wall includes lower wall 156. The cyclone wall 148 is positioned in the filtration member housing 120 such that it is spaced from the sidewall 130, top wall 132, and bottom wall 134 of the filtration member housing 120. A plurality of struts 158 support the cyclone wall 148 within the filtration member housing 120. The space between the lower wall 156 of the cyclone 144 and the bottom wall 134 of the filtration member housing 122 forms a dirt collection chamber 160.

The cyclone 144 further includes a cyclone air inlet 162, and a cyclone air outlet 164. The cyclone air inlet 162 extends from a first end (not shown) that is in communication with the hose 117, through the sidewall 130 of the filtration member housing 120, to a second end (not shown) that is in communication with the cyclone chamber 150. The cyclone air outlet 164 extends along the axis 146, from a first end 170 that is positioned within the cyclone chamber 150, through the lower wall 156, and to a second end 172 that is in communication with the interior of the motor housing 122. A screen (not shown) is preferably mounted over the first end 170 of the cyclone air outlet.

In use, air flows from the hose 117 into the cyclone chamber 150 through the cyclone air inlet 162. In the cyclone chamber 150, the air flows within the cyclone wall 148 in a cyclonic pattern, and particulate matter is separated from the air. The particulate matter exits the cyclone chamber 150 through the first end 152, and settles in the dirt collection chamber 160. The air exits the cyclone chamber 150 through the cyclone air outlet 164, and enters the motor housing 122.

The dirt collection chamber 160 may be emptied in any suitable manner. In the embodiment shown, the bottom wall 134 is pivotally mounted to the sidewall 130, and serves as an openable door. The dirt collection chamber 160 may be emptied by removing the filtration member housing 120 from the suction motor housing 124, as described hereinabove, and pivoting the bottom wall 134 away from the sidewall 130.

Referring still to FIG. 2, the motor housing 122 houses the suction motor 126, a pre-motor filter 176 (shown in FIGS. 5 and 6A and 6B) upstream of the suction motor 126 and downstream of the cyclone 144, and a post-motor filter 178 downstream of the suction motor 126 and upstream of the clean air outlet 104.

The pre-motor filter 176 extends across the open top 140 of the motor housing 122, and has an upstream side 180 that faces and is spaced from the cyclone air outlet 164, and an opposed downstream side 182 that faces the bottom wall 138 of the motor housing 122. The pre-motor filter 176 is supported within the motor housing 122 by an apertured support wall 184 (seen most clearly in FIG. 3), which extends across the motor housing 122. The pre-motor filter 176 is sized to be generally snugly received within the motor housing 122, such that air entering the motor housing 122 from the cyclone air outlet 164 passes through the pre-motor filter 176 in a direction indicated by arrow A (i.e. the pre-motor filter has a direction of airflow indicated by arrow A). The pre-motor filter 176 may be any suitable type of filter. Preferably, the pre-motor filter includes a foam layer 186 and a felt layer 188.

Referring to FIG. 4, when the filtration member housing 120 is lifted off of the motor housing 122, the pre-motor filter 176 is exposed, and may be removed, replaced, or cleaned.

Referring back to FIG. 2, the suction motor 126 is housed within the motor housing 122, in a motor section 173. The motor section 173 is beneath the apertured support wall 184. The motor section 173 has a first end 175 and an opposed second end 177.

The suction motor 126 may be any suitable type of suction motor, and preferably has a fan portion 199 and a motor portion 197. In the embodiment shown, the suction motor 126 extends along a longitudinal axis 190 that is generally vertically extending. The suction motor 126 has an air inlet end 179, an opposed distal end 181, and an air inlet direction, indicated by arrow A3. The first end 175 of the motor section 173 is at the air inlet end 179 of the suction motor 126, and the second end 177 is at the distal end 181 of the suction motor 126. Preferably, the pre-motor filter 176 is positioned at the air inlet end 179 of the suction motor 126, and the direction of airflow of the pre-motor filter 176 is aligned with the air inlet direction of the suction motor 126.

The post motor filter 178 is housed in a post-motor filter chamber 183. In the example shown, the post motor filter chamber 183 is entirely within the motor section 173. In alternate embodiments, only a portion of the post motor filter chamber 183 may be within the motor section 173, or the post motor filter chamber 183 may be outside of the motor section 173. Preferably at least a third, more preferably at least two thirds and most preferably at least 75% of the post motor filter chamber 183 is positioned within the motor section 173. An advantage of this design is that the height of the motor housing may be shortened, this permits the suction motor, and other components positioned on top of the motor housing, to be located lower on the upper section but still spaced from the top of the floor cleaning head.

The post motor filter chamber 183 has an inlet end 185, which is adjacent the suction motor 126, and an outlet end 187, which is adjacent the clean air outlet 104. Preferably, at least a portion of the inlet end 185 is laterally spaced from and faces the suction motor 126. For example, the air inlet end 185 of the filter chamber 183 may be spaced less than 3 inches from the suction motor 126, and preferably less than 1.5 inches from the suction motor. The direction of airflow through post motor filter chamber 183, indicated by arrow A4, is transverse to the air inlet direction of the suction motor, indicated by arrow A3.

The post motor filter chamber 183 is preferably openable, and the post-motor filter 178 is preferably removably mounted in the post motor filter chamber 183. For example, as shown in FIG. 5, the clean air outlet 104 may be defined in a grate 189 that is removably mountable to the suction motor housing 122. For example, one or more latch members 191 may be provided to removably latch the grate 189 to the suction motor housing 126. Alternately, the grate 189 may be pivotally openable with respect to the suction motor housing 126. When the grate 189 is opened or removed from the suction motor housing 122, the post motor filter 178 may be removed from the post motor filter chamber 183, and may optionally be replaced or cleaned, for example.

Referring to FIGS. 5, 6A, and 6B, the inlet end 185 of the post motor filter chamber 183 includes a finger guard 191. The finger guard generally prevents or minimizes the risk of a users fingers contacting the suction motor 126 when the post motor filter chamber 183 is open and the post motor filter 178 is removed from the post motor filter chamber 183. The finger guard 191 may be of any suitable configuration. In the embodiment shown, the finger guard 191 is in the form of a grate, which extends partially around the suction motor 126 and is integral with the suction motor housing 122.

The post-motor filter 178 may be any suitable type of filter, such as a HEPA filter.

It is possible that in some instances, the airflow passage may become fully or partially clogged. For example, a large object, such as a ball of hair, may become lodged anywhere in the airflow passage, such as in the floor cleaning head 106. For further example, the pre-motor filter 176 may become clogged with particulate matter. If this occurs, the suction motor 126 may burn out. Referring still to FIG. 2, a bleed-valve 101 is provided in the motor housing 122. If a clog occurs in the airflow passage, the pressure in the motor housing 122 will decrease. The bleed valve 101 is preferably configured to open when the pressure decreases, and allow air to flow through the motor housing 122 to the clean air.

Various apparatuses or methods are described above to provide an example of each claimed invention. No example described above limits any claimed invention and any claimed invention may cover processes or apparatuses that are not described above. The claimed inventions are not limited to apparatuses or processes having all of the features of any one apparatus or process described above or to features common to multiple or all of the apparatuses described above. 

1. An upright surface cleaning apparatus comprising: (a) a floor cleaning head having a dirty air inlet; (b) air flow passage extending from the dirty air inlet to a clean air outlet; (c) an upright section moveably mounted to the surface cleaning head between an storage position and an in use position and comprising a filtration member and a suction motor provided in the air flow passage, the suction motor having an air inlet end, an opposed distal end and an air inlet direction; and a motor housing, the motor housing comprising a motor section in which the suction motor is provided, the motor section having a first end at the air inlet end of the suction motor and an opposed second end at the distal end of the suction motor; (d) an openable post motor filter chamber provided in the motor housing and having an inlet end and an outlet end, at least a portion of the filter chamber is provided in the motor section, the inlet end includes a finger guard and the filter chamber has a direction of airflow that is transverse to the air inlet direction of the suction motor; and, (e) a post motor HEPA filter removably mounted in the filter chamber.
 2. The surface cleaning apparatus of claim 1 wherein the inlet end of the filter chamber is positioned adjacent the suction motor.
 3. The surface cleaning apparatus of claim 1 wherein at least a portion of the inlet end of the filter chamber is laterally spaced from and faces the suction motor.
 4. The surface cleaning apparatus of claim 1 further comprising a pre-motor filter positioned at the air inlet end of the suction motor.
 5. The surface cleaning apparatus of claim 4 further comprising a pre-motor filter positioned at the air inlet end of the suction motor and the pre-motor filter has a direction of airflow that is aligned with the air inlet direction of the suction motor.
 6. The surface cleaning apparatus of claim 5 wherein the filtration member comprises a cyclone, the cyclone comprises an air inlet and an air outlet and the air outlet of the cyclone is spaced from and faces the pre-motor filter.
 7. The surface cleaning apparatus of claim 1 wherein the air inlet end of the filter chamber is spaced less than 3 inches from the suction motor.
 8. The surface cleaning apparatus of claim 1 wherein the air inlet end of the filter chamber is spaced less than 1.5 inches from the suction motor.
 9. An upright surface cleaning apparatus comprising: (a) a floor cleaning head having a dirty air inlet; (b) air flow passage extending from the dirty air inlet to a clean air outlet; (c) an upright section moveably mounted to the surface cleaning head between an storage position and an in use position and including a motor housing; (d) a filtration member and a suction motor provided in the air flow path, the suction motor having an air inlet end, an opposed distal end and an air inlet direction; (e) an openable post motor filter chamber provided in the motor housing and having an inlet end and an outlet end, at least a portion of the inlet end is laterally spaced from and faces the suction motor, the inlet end including a finger guard; and, (f) a post motor HEPA filter removably mounted in the filter chamber.
 10. The surface cleaning apparatus of claim 9 wherein the inlet end of the filter chamber is positioned adjacent the suction motor.
 11. The surface cleaning apparatus of claim 9 wherein the motor housing comprises a motor section in which the suction motor is provided, the motor section having a first end at the air inlet end of the suction motor and an opposed second end at the distal end of the suction motor and at least a portion of the filter chamber is provided in the motor section.
 12. The surface cleaning apparatus of claim 9 further comprising a pre-motor filter positioned at the air inlet end of the suction motor.
 13. The surface cleaning apparatus of claim 9 wherein the filter chamber has a direction of airflow that is transverse to the air inlet direction of the suction motor.
 14. The surface cleaning apparatus of claim 13 further comprising a pre-motor filter positioned at the air inlet end of the suction motor and the pre-motor filter has a direction of airflow that is aligned with the air inlet direction of the suction motor.
 15. The surface cleaning apparatus of claim 14 wherein the filtration member comprises a cyclone, the cyclone comprises an air inlet and an air outlet and the air outlet is spaced from and faces the pre-motor filter.
 16. The surface cleaning apparatus of claim 9 wherein the air inlet end of the filter chamber is spaced less than 3 inches from the suction motor.
 17. The surface cleaning apparatus of claim 9 wherein the air inlet end of the filter chamber is spaced less than 1.5 inches from the suction motor. 